System and method for portable dry chemical injection

ABSTRACT

The present invention provides a system to precisely deliver dry chemicals, and to an apparatus and method to reliably and accurately deliver dry chemicals used during drilling operations. An additional aspect of the present invention is to provide a dry chemical delivery system that is modular and portable. Further, the apparatus may be configured to automatically meter and control multiple dry chemicals into a common line for use in drilling operations.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefits of and priority, under 35 U.S.C. §119(e), to U.S. Provisional Application Ser. No. 61/716,199, filed Oct. 19, 2012, entitled “SYSTEM AND METHOD FOR PORTABLE DRY CHEMICAL INJECTION,” herein incorporated by reference in its entirety for all purposes.

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to a system to precisely deliver dry chemicals and, in particular, to an apparatus and method for reliably and accurately delivering dry chemicals used during drilling operations.

BACKGROUND OF THE INVENTION

Worldwide demand for energy continues to expand. One of the dominate sources of energy for decades has been and continues to be oil. However, supplies of conventional oil are increasingly limited given the volume of exploration and recovery that has occurred. Conventional recovery techniques are encountering heightened difficulty in recovering remaining deposits of conventional oil. Thus, alternative oil sources and alternative means of recovery have become more vital. Researchers have long investigated recovery of unconventional sources of oil such as those contained in oil shale and oil sands, and non-traditional recovery means such as those involving hydraulic fracturing.

Hydraulic fracturing, also known as “fracking”, is the process of inducing cracks or fractures in rock or carbonate deposit layers through injection of a pressurized fluid. The fractured rock then releases oil, natural gas or other desired recovery substances. Typically the fluid used in hydraulic fracturing is chemically-treated water and sand. Although hydraulic fracturing has been used for many years in conventional vertical drilling, its use was typically limited to stimulating highly permeable single wells. However, with the relatively recent advent of directional drilling and favorable economics of unconventional oil sources such as oil sands and oil shale, the use of hydraulic fracturing has grown extensively.

A critical parameter for effective hydraulic fracturing is the reliable and accurate application of chemicals with the fracturing injection fluid. More specifically, the dry chemicals mixed with the injected water must be precisely controlled for effective fracturing. The mixture must also be reliable and accurate to conform to required environmental regulations, such as reporting requirements of the volume and ratio of the one or more dry chemicals added to the water before injection into the well.

Conventionally, dry chemicals used in hydraulic fracturing are combined or mixed before beginning a fracking operation. Such a process may be inefficient because, for example, the premixed material may degrade with time and have to be disposed of in situations where the fracking job is postponed. Also, such pre-mixing of dry chemicals limits on-site adaptation of dry chemical proportions for particular hydraulic fracturing operations, and does not allow real-time monitoring and control of precise quantities of dry chemicals. Additional background on preparation and delivery of substances used in hydraulic fracturing operations and well injections is provided in U.S. Pat. Nos. 4,716,932 by Adams and 4,635,727 to Anderson, and U.S. Patent Application Publication No. 2012/0225800 to Hendrickson, the entire disclosures of each of which are incorporated by reference.

What is needed is a modular and portable system to precisely deliver dry chemicals used during drilling operations, the system adaptable to automatically meter and control multiple dry chemicals into a common line.

SUMMARY OF THE INVENTION

It is one aspect of the present invention to provide a system to precisely deliver dry chemicals and, in particular, to an apparatus and method for reliably and accurately delivering dry chemicals used during drilling operations. An additional aspect of the present invention is to provide a dry chemical delivery system that is modular and portable. Further, the apparatus may be configured to automatically meter and control the multiple dry chemicals into a common line for use in drilling operations.

In one embodiment of the invention, a dry chemical delivery system is provided, the system comprising: a first receiving container having a receiving portion and delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion and configured to receive the first dry product and deliver a user-selectable volume or rate of the first dry product; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; and a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; wherein the first dry product in the first hose is delivered to a delivery site.

In another embodiment of the invention, a method for delivery of a dry product to a delivery site is provided, the method comprising: positioning a dry product delivery system proximate to a delivery site, the dry product delivery system comprising: a first receiving container having a receiving portion and a delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion and configured to receive the first dry product and deliver a user-selectable volume or rate of the first dry product; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; and a computer in communication with the first meter, the computer adapted to receive a user-selectable volume or rate of first dry product to the first air channel; inputting a selected volume or rate of first product to the first air channel; providing a first dry product to the first receiving container; wherein the first dry product as contained in the first hose is delivered to the delivery site.

In a further embodiment of the invention, a dry product delivery system is provided, comprising: a first receiving container having a receiving portion and delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container, and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion, receive the first dry product, and deliver a user-selectable volume or rate of the first dry product; a computer in communication with the first meter, the computer adapted to receive a user-selectable volume or rate of first dry product to the first air channel; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; and a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; wherein the computer records the measurement of the weight of the first dry product, wherein the first dry product is delivered to a delivery site.

The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material.”

This Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention, and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

The above-described benefits, embodiments, and/or characterizations are not necessarily complete or exhaustive, and in particular, as to the patentable subject matter disclosed herein. Other benefits, embodiments, and/or characterizations of the present disclosure are possible utilizing, alone or in combination, as set forth above and/or described in the accompanying figures and/or in the description herein below. However, the Detailed Description of the Invention, the drawing figures, and the exemplary claim set forth herein, taken in conjunction with this Summary of the Invention, define the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above, and the detailed description of the drawings given below, serve to explain the principals of this invention.

FIG. 1A depicts a side view of the system to deliver dry chemicals in one embodiment of the present invention;

FIG. 1B depicts a block diagram of the system to deliver dry chemicals in one embodiment of the present invention;

FIG. 2 depicts a side view of the system to deliver dry chemicals in an alternate embodiment of the present invention;

FIG. 3A depicts a side view of a series arrangement of two embodiments of the system to deliver dry chemicals of the present invention;

FIG. 3B depicts a partial side view of a series arrangement of two embodiments of the system to deliver dry chemicals of the present invention;

FIG. 3C depicts a cross-sectional side view of components of one embodiment of the system to deliver dry chemicals in one embodiment of the present invention;

FIG. 4A depicts a side view of an alternate series arrangement of two embodiments of the system to deliver dry chemicals of the present invention; and

FIG. 4B depicts a side view of another alternate series arrangement of two embodiments of the system to deliver dry chemicals of the present invention.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

FIGS. 1-4 show various embodiments of the system 2 to deliver dry chemicals of the present invention.

Referring to FIG. 1A, the elements of the system 2 to deliver dry chemicals are depicted. Dry chemicals are provided to airtight Container 6 via Access Hatch 4. The chemicals flow downward by gravity to a precision Meter 10. The weight of the dry chemicals is measured by one or more Load Cells 8 in communication with the Container 6. Meter 10 monitors and controls the delivery of dry chemical to Air Channel 12. The dry chemicals are translated from Air Channel 12 via Coupler 16 to a Flexible Hose 18 by air pressure provided by variable speed Blower Fan 14. Dry chemical continues to translate Flexible Hose 18 to Release Hose 20, negotiates Elbow 22 and then enters Diffuser 24. The Diffuser 24, among other things, exhausts air flow so as to lower the speed of the dry chemical before delivery of dry chemical to a Blending Hopper 26. Other materials, such as sand or proppant, may be blended with the dry chemical in the Blending Hopper 26 before ultimately being delivered to a drilling well.

Referring FIG. 1B, a block diagram of the system 2 to deliver dry chemicals in one embodiment of the present invention is provided. Dry chemicals are provided to Container 6. One or more Load Cells 8 measure and monitor the weight of the provided dry chemical as supplied to the Container 6. The dry chemical then sequentially passes through Meter 10 and Air Channel 12, as urged by Blower fan 14. One or more of Container 6, Load Cell 8, Meter 10, Blower Fan 14 and Air Channel 12 are controlled and/or monitored by Controller and Display 28. After leaving Air Channel 12, the dry chemicals pass through Flexible Hose 18 and Release Hose 20 to Diffuser 24. The Diffuser 24, among other things, exhausts air flow so as to lower the speed of the dry chemical before delivery of dry chemical to a Blending Hopper 26 before use in a drilling operation.

The device or system 2 as depicted in FIGS. 1A and 1B may also be referred to as a “Power Pod” given the inclusion of its Blower Fan 14 element. The embodiment of the invention as depicted in FIG. 2 does not include Blower Fan 14 element and may also be referred to as a “Nurse Pod.”

Referring to FIG. 2, the Nurse Pod device or system 2′ is configured to supplement a Power Pod device 2. In system 2′, dry chemicals are provided to airtight Container 6 via Access Hatch 4. The chemicals flow downward by gravity to a precision Meter 10. The weight of the dry chemicals is measured by one or more Load Cells 8 in communication with the Container 6. Meter 10 monitors and controls the delivery of dry chemical to Air Channel 12. The dry chemicals are translated from Air Channel 12 via Coupler 12 to a Flexible Hose 18. The dry chemicals advance downstream by air pressure provided by variable speed Blower Fan 14 of a Power Pod system 2 (not shown). Dry chemical continues to translate Flexible Hose 18 and, optionally, to Extended Flexible Hose 18′.

FIGS. 3A and 3B depict side views of a series arrangement 30 of a Power Pod system 2 with two Nurse Pod systems 2′. In such a configuration, three (3) different dry chemicals may be precisely metered and controlled before delivery to a Diffuser 24 and ultimately to a drilling well.

Referring to FIGS. 3A and 3B, a power pod system 2 is depicted with blower fan 14, air channel 12 and meter 10 _(p). System 2 delivers dry chemical to hose 18 as urged by blower fan 14. Meter 10 _(p) delivers user-selected volume or rate of dry chemical, as input to power pod system 2 to its adjacent hose 18. Two Nurse Pod systems 2′ are shown positioned downstream from Power Pod 2, each of which comprise respective meters 10 ₁ and 10 ₂ delivering respective dry chemicals at user-selected volumes or rates. At each successive meter, that is, at respective meters 10 ₁ and 10 ₂, the upstream dry chemical(s) are blended. For example, at meter 10 ₁ the dry chemical from System 2 and meter 10 _(p) is blended with the dry chemical received from Nurse Pod 1 at meter 10 ₁.

Referring to FIG. 3C, a cross-sectional side view of a meter 10 and air channel 12 is provided. The dry chemical received from the container enters Meter 10. The Meter 10 rotates so as to deliver the dry chemical at a user-selected or user-defined rate or volume. The delivered dry chemical then is urged downstream in air channel 12 by blower fan 14.

Referring to FIG. 4A, a side view of an alternate series system with auger 32 is depicted. The series system with auger 32 comprises three Nurse Pod systems 2′. Similar to the series system 30 of FIGS. 3A-B, the series system with auger 32 enables three (3) different dry chemicals to be precisely metered and controlled before ultimately delivered to a drilling well via a blending hopper. Note that no Power Pod system 2 is required with associated blower fan 14, because the auger 38 advances the metered dry product. That is, the auger 38 serves, among other things, to urge the dry chemicals from the series of three Nurse Pod systems 2′ to a blending hopper, as shown by the (left to right) arrows within the auger 38. In some embodiments, the auger 38 also mixes and/or blends the dry chemicals. The auger 38 comprises external auger housing 36, auger drive shaft 40 as driven by auger drive motor 42 and engaged with auger bearing support 34. Each System 2′ delivers dry chemical to auger 38. The three Nurse Pod systems 2′ comprise respective meters 10 ₁, 10 ₂ and 10 ₃ delivering respective dry chemicals at user-selected volumes or rates. At each successive meter, that is, at respective meters 10 ₁, 10 ₂ and 10 ₃, the upstream dry chemical(s) are blended. In some embodiments, a blower fan 14 (not shown) may be disposed adjacent the auger bearing support 34 to further urge the dry chemicals from the series of Nurse Pod systems 2′ to a blending hopper as shown by the arrows within the auger 38.

Referring to FIG. 4B, a side view of an alternate series system with conveyor 46 is depicted. The series system with conveyor 46 comprises three Nurse Pod systems 2′. Similar to the series system 30 of FIGS. 3A-B and the series system with auger 32 of FIG. 4A, the series system with conveyor 48 enables three (3) different dry chemicals to be precisely metered and controlled before ultimately delivered to a drilling well via a blending hopper. Note that no Power Pod system 2 is required with associated blower fan 14, because the conveyor 48 advances the metered dry product. The conveyor 48 serves, among other things, to urge the dry chemicals from the series of three Nurse Pod systems 2′ to a blending hopper, as shown by the (left to right) arrows within the conveyor 48. In some embodiments, the conveyor 48 also mixes and/or blends the dry chemicals. The conveyor 48 comprises conveyor housing and conveyor egress 50. Three Nurse Pod systems 2′ are shown, each of which comprise respective meters 10 ₁, 10 ₂ and 10 ₃ delivering respective dry chemicals at user-selected volumes or rates. At each successive meter, that is, at respective meters 10 ₁, 10 ₂ and 10 ₃, the upstream dry chemical(s) are blended. The mixed dry chemicals leave or egress from the conveyor 48 via the conveyor egress 50. In some embodiments, a blower fan 14 (not shown) may be disposed adjacent the proximal conveyor 48 location, i.e. the left end of conveyor 48 as depicted in FIG. 4B, to further urge the dry chemicals from the series of three Nurse Pod systems 2′ to a blending hopper as shown by the arrows within the conveyor 48.

In one embodiment, container is configured as an airtight container that contains an access/fill door at the top. This configuration may be provided for either or both of the Nurse Pod and the Power Pod systems. The access/fill door has a seal and a latch in order to lock and prevent dust or contents from escaping. In another embodiment, dry chemical is delivered to a particular container by any means known to those skilled in the art, to include via pneumatics such as a pneumatic pump which blows dry chemical into a particular container.

In one embodiment, the compartment is mounted on four legs that mount to a sub frame, with pivot points where scale Load Cells 8 are mounted. In one embodiment, the load cells are used for functions comprising loading the proper amount of dry chemical product for the specific job and to measure accuracy of output of the dry chemical. Other configurations of the container are provided in further embodiments, such as three legs or an entirely encapsulated “box-style” configuration. In one embodiment, the container, and/or additional or all other components of the system, are portable and modular. In one embodiment, the dry chemical in the container is a blend of more than one dry chemical.

The term “dry product” means any substance of low moisture content that generally behaves as a solid, to include dry chemicals and agricultural seeds. The term “dry chemical” may be any chemical or substance with properties that allow flow into an air channel and subsequent urging by a blower fan. In hydraulic fracturing applications, these dry chemicals comprise a variety of chemicals known to those skilled in the art, to include borate salts, potassium chloride, ammonium bisulfate, sodium or potassium carbonate, ScaleSorb™ and Oxyscavenger. A listing of commonly used chemicals in hydraulic fracturing may be found, for example, in “Modern Shale Gas Development in the United States: A Primer,” U.S. Dept. of Energy, April, 2009 and also the Chemical Disclosure Registry “Frac Focus” (http://fracfocus.org/), the entire disclosures of each of which are incorporated by reference.

However, other applications beyond hydraulic fracturing and other dry chemicals/substances may be used, such as those in agricultural applications. For example, the system may be used to precisely deliver seed to agricultural planters and/or sprayers.

In one embodiment, the blower fan is a variable speed blower fan which is adjustable manual or automatically. The blower fan may be computer-controlled. The blower fan may be driven by any means known to those skilled in the art, to include electric, hydraulic and pneumatic. In one embodiment, the blower fan is a REM™ blower fan, such as a centrifugal in-line fan blower.

In one embodiment, the meter is a precision meter mounted at the bottom portion of the container, and controlled by an electric motor drive with an internal tachometer. The motor speed may be controlled through user-selection or through computer control. The motor speed of the meter may be calibrated through a computer to measure the amount of (dry chemical) product released per revolution, which will correlate to the application amount need over an X amount of time as per the prescription for a particular application, for example, for a particular zone of a hydraulic fracturing drilling operation.

In one embodiment of the system with auger, the auger is configured as known by one skilled in the art, to include those commercially available and/or available as off-the-shelf augers. For example, the auger may be an auger manufactured by Brock Grain Systems, to include the Brock© 25-inch diameter Boot System and the Brock© FLEX-AUGER© Feed Delivery System. In one embodiment, a plurality of augers are configured to engage with the system.

In one embodiment of the system with conveyor, the conveyor is configured as known by one skilled in the art, to include those commercially available and/or available as off-the-shelf conveyors. For example, the conveyor may be a conveyor manufactured by Global Industries, Inc. to include Hutchinson/Mayrath, and those manufactured by Meridian Manufacturing Inc. In one embodiment, a plurality of conveyors are configured to engage with the system. In one embodiment, the conveyor is a belt conveyor.

In one embodiment of operation for a hydraulic fracturing drilling operation application, a specific amount of dry chemical to be blended/injected into a gel mix in a downstream blender hopper per a specific time frame is first determined. The device is then employed to deliver this amount of dry chemical to the hopper as follows. Dry chemical is loaded in container via access hatch. The dry chemical then flows, via gravity or other means, out of the container to the meter. The meter rotates and releases the dry chemical into the air channel. With the blower fan creating the desired air velocity, the dry chemical enters the air stream in the air channel and is propelled or urged through the flexible hose until it reaches a release hose. The stream of dry chemical and air is then angled downward with an elbow and then enters a diffuser. The diffuser exhausts the access air flow, thus lowering the velocity of the dry chemical, gently dropping it into the gel blending hopper to mix with the other materials (sand, proppant, etc). By releasing the air prior to release, dust particles are drastically reduced for added safety of the workers nearby. This example describes the system configured to deliver one dry chemical.

However, multiple dry chemicals may also be delivered at known rates or volumes using the system. For example, many times during a hydraulic fracturing drilling operation application more than one dry chemical must be added to the gel/proppant mixture for blending. When multiple dry chemical products are needed at a particular hydraulic fracturing job, additional system “pods” may be added in sequence, as shown in FIGS. 3A-B and FIGS. 4A-B. Each of the one or more Nurse Pods are added to create a “chain” with a common air stream to propel their respective one or more additional dry chemical products to a common outlet for release into the gel/proppant blender hopper. Each of the meters (i.e. of the Power Pod and each of the one or more Nurse Pods) can be controlled from a single monitor, calibrated individually, controlled individually, and be included or excluded from each stage of hydraulic fracturing, depending on necessity for that particular stage. In particular, the invention is not limited to series arrangements with one (1) or two (2) nurse pods. That is, further embodiments with three (3) or more nurse pods are disclosed and captured by the invention. In one embodiment, a CANBUS electronics system is used.

Connections between systems, e.g. between a Power Pod and a Nurse Pod, are through couplers. The couplers may be of any type known to those skilled in the art, to include hose clamps. In one embodiment, the hose connections are quick release “cam lock” style coupler system for quick connections between Power Pod and adjoining Nurse Pods. Material composition of the couplers will primarily be stainless steel, but in certain configurations in the Pod Chain aluminum “cam locks” will be used. The “cam lock” connections will be used from the fan to the air channel and with all other hose connections.

In a preferred configuration, the hose diameter is between approximately 1 to 12 inches, in a more preferred configuration, the hose diameter is between approximately 2 and 10 inches, and in a most preferred configuration, the hose diameter is between approximately 2 and 6 inches. In one preferred configuration, the hose is 4 inches in diameter and is a high wear resistant rubber hose.

In one preferred embodiment, the blower fan diameter is approximately between 3 and 14 inches, in a more preferred embodiment is between about 4 and 12 inches, and in a most preferred embodiment is between 6 and 10 inches. In one embodiment, the blower fan is a Crary™ centrifugal fan. The fan may be adapted to conform to the air output needed. In other embodiments, the blower fan comprises forward curve, radial, backward inclined, airfoil, or radial tip style blade configurations.

The precision meter may be any meter known to those skilled in the art for metering dry product, to include meters typically used for metering seed on agricultural planters. The meter used on the system pods (i.e. either in power pod or in nurse pod configuration) may be manufactured by Horsch Maschinen™. The Horsch™ precision meter may contain a specialized “roller” with cells. As the meter rotates via an electric motor, the cells fill with product and then release into the air channel when the meter roller is on the bottom radius of the rotation. The precision meter may be controlled with a Dunker™ Motor. The Dunker™ Motor has an internal tachometer, which will relay rotation rpm back to a CANBUS electronic control system. In a preferred configuration, the motor operates between 5 and 150 RPM, in a more preferred configuration, the motor operates between 5 and 125 RPM.

Prior to applying granular product, the meter/motor is calibrated as follows.

Calibration is factored by rotating the meter via the motor X number of revolutions. The CANBUS control system reads the number of rotations from the tachometer on the motor. The product that is metered out in the X number of rotations is then weighed, and that total weight is entered into the CANBUS control system in a unit of weight measurement (ounces). With the X number of rotations and the total weight released, the CANBUS control system calculates the amount of product (ounces) that is released per rotation of the meter. With this “calibration factor”, a specific time frame (0.00-1,000.00 minutes) can be entered into the CANBUS control system. Once the specific time frame is entered, a total amount of product (0.00 lbs) is entered. When the meter is engaged at this point it will meter out the entered amount of product over the entered specific time frame and then cease rotation. For example:

-   -   Time Frame (5.45 minutes)     -   Product to Be Applied (8.44 lbs)     -   Motor Cal Number (1.2 ounces)     -   The meter will rotate 112.5 times within the given time frame,         thus rotating a total of 20.6 rpm until the time frame ends.

The meter can be controlled by any means known to those skilled in the art, to include by an electric motor, a hydraulic motor and pneumatic motor. There may be a tachometer for rotation count and rpm feedback. The system is based on X amount of product that is released per rotation.

In one embodiment, each pod is mounted to a frame and constructed with a four-point scale system. The scales, i.e. load cells, may be compression transducer load cells from Digit Star™. The load cells may be of type differential weigh beam or shear beam type load cells. Scale monitor system will be either on a remote display or linked into the CANBUS control system.

In one embodiment, the container tank is constructed of a corrosive resistant material. In one embodiment, the Power Pod and the adjoining Nurse Pods are made mobile via an enclosed trailer; a rail system may be installed in the floor of the trailer to slide the Power Pod in first then adjoining Nurse Pods according to hydraulic fracturing job needs.

In yet another embodiment, the disclosed systems and methods may be partially implemented in software that can be stored on a storage medium to include a computer-readable medium, executed on programmed general-purpose computer with the cooperation of a controller and memory, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this disclosure can be implemented as program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like. The system can also be implemented by physically incorporating the system and/or method into a software and/or hardware system.

In one embodiment, one or more computers are used to control, among other things, the rate or volume of dry product through one or more meters. In one embodiment, a user selectively inputs a volume or rate of one or more dry products through or into one or more meters. In one embodiment, the user interacts with the computer through any means known to those skilled in the art, to include a keyboard and/or display to include a touch-screen display. The term “computer-readable medium” as used herein refers to any tangible storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored.

The term “display” refers to a portion of one or more screens used to display the output of a computer to a user. A display may be a single-screen display or a multi-screen display, referred to as a composite display. A composite display can encompass the touch sensitive display of one or more screens. A single physical screen can include multiple displays that are managed as separate logical displays. Thus, different content can be displayed on the separate displays although part of the same physical screen.

Experimental Results

The following experimental results are with respect to a system device and method to apply granular chemicals into a blended material process for use in the hydraulic fracturing drilling operations. These results are sample results and are not intended to limit the invention. The outlines provided are a guide to the design, software creation, and expanded capacities of an electronic control system to run a metering device to apply such granular chemicals.

The basic parameters to meter a dry chemical product include:

-   -   1. Product must be calibrated in ounces     -   2. Calibration must be calculated using two decimal points (ex.         12.39 onces)     -   3. Application Rate must be calculated to pounds per x number of         minutes     -   4. A total product amount needs to be applied within a given         time frame     -   5. The minute or minutes of time must be entered as minutes and         include two decimals (ex. 10.8 min)

Settings Parameters:

-   -   1. Product Application (total pounds for time period) must range         from 0.00 to 10,000.00 lbs.     -   2. Time period must range from 0.00 to 1,000.00 minutes         Example: Enter “5.45 lbs to be applied at a consistent rate over         20 minutes”

Monitor Display: Operator needs to have a front page visual of:

-   -   1. Fan RPM     -   2. Engine RPM (if on power unit)     -   3. System Voltage and Amps     -   4. PSI/CI of pressurized tank     -   5. Tank fill indicator

Functions to be Changeable on front page:

-   -   1. Working Minutes for application     -   2. Total pounds to be applied during set minute range     -   3. ON/OFF for each product

The operator on of the monitor must be able to:

-   -   1. Turn each product (up to 4) ON and OFF individually     -   2. Must be a main ON/OFF for emergency shut down     -   3. Application rate must be entered manually     -   4. Time period must be entered manually     -   5. Page for calibration of each product     -   6. On each stage of application must be able to enter in stage         information, usually up to 10 digits

System Hardware to be monitored or controlled by electronics and monitor:

-   -   1. Fan rpm sensor     -   2. Engine rpm sensor (if applied)     -   3. Pressure sensor in tank     -   4. Velocity/Partical sensor     -   5. Bin level sensor (eyes, radar, mechanical, etc)

The Power POD will be the only POD that will have a fan. This will be the only POD that will need a fan sensor. The Power POD will include:

-   -   1. Fan     -   2. Meter     -   3. Electronics for monitoring and metering

The nurse pod will not have a fan. Each POD must have the ability to connect and function with other PODs. At least four (4) dry granular POD's must be able to be hooked in a BUS and control simultaneously.

Nominal System Operational Requirements:

-   -   1. Ability to operate Horsch™ VDO motor or other rotational         devices with a tachometer     -   2. Operate on 12 Volt power source (amps TBD)     -   3. Ability to add PODs in a BUS and control each independently

Additional System Requirements

-   -   1. Ability to use a tablet (Ipad, etc) or laptop computer to         control system and use as monitor     -   2. Ability to use tablet or laptop as a wireless device to         control the system, max 500 feet between system and         tablet/laptop     -   3. Ability to have remote access to the system, less ability to         change anything, for observation only, in real time. This could         be accomplished through a password protected website that         customers, managers, and other parties could access to keep tab         on application process.     -   4. Ability to create Excel or xml file showing zones showing         stage number, length of time, actual product applied,         application amount, time period on both a chart and on a         spreadsheet. This file must be printable and transferable in an         electronic form

As in prescription application in the agricultural industry (seeders, sprayers, etc), the system would advance to have the ability for the operator to load a file for each job. This job may have many individual stages. Operator would be able to load the predetermined file, “frac prescription”, then have a list of stages. When the stage is located and clicked, the rates for each product would automatically load for stage selected. Once these have loaded, the operator needs the ability to change these manually as changes may need to be made.

One of ordinary skill in the art will appreciate that embodiments of the present disclosure may be constructed of materials known to provide, or predictably manufactured to provide the various aspects of the present disclosure. These materials may include, for example, stainless steel, titanium alloy, aluminum alloy, chromium alloy, and other metals or metal alloys. These materials may also include, for example, carbon fiber, ABS plastic, polyurethane, and other fiber-encased resinous materials, synthetic materials, polymers, and natural materials. The system and its elements could be flexible, semi-rigid, or rigid and made of materials such as stainless steel, titanium alloy, aluminum alloy, chromium alloy, and other metals or metal alloys, carbon fiber, ABS plastic, polyurethane, and other fiber-encased resinous materials, synthetic materials, polymers, and natural materials.

One of ordinary skill in the art will appreciate that embodiments of the present disclosure as provided in FIGS. 1-4 may be used in applications other than drilling. For example, in applications in which precise and reliable supply of dry product are required. For example, to precisely and accurately deliver dry agricultural product, such as feed or seed.

Reference No. Component  2 System  2′ Nurse System  4 Access Hatch  6 Container 10_(p) Power Pod Meter 10₁ Nurse Pod 1 Meter 10₂ Nurse Pod 2 Meter 10₃ Nurse Pod 3 Meter 12 Air Channel 14 Blower Fan 16 Coupler 18 Flexible Hose 18′ Extended Flexible Hose 20 Release Hose 22 Elbow 24 Diffuser 26 Blending Hopper 28 Controller and Display 30 Series System 32 Series System with Auger 34 Auger Bearing Support 36 Auger Housing 38 Auger 40 Auger Drive Shaft 42 Auger Drive Motor 44 Auger Egress Port 46 Series System with Conveyor 48 Conveyor 50 Conveyor Egress 

What is claimed is:
 1. A dry product delivery system, comprising: a first receiving container having a receiving portion and delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion and configured to receive the first dry product and deliver a user-selectable volume or rate of the first dry product; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; and a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; wherein the first dry product in the first hose is delivered to a delivery site.
 2. The system of claim 1, further comprising a diffuser interconnected with the first hose and adapted to decrease the speed of the first dry product.
 3. The system of claim 1, further comprising a computer in communication with at least one of the first meter, a blower fan and the first sensor.
 4. The system of claim 3, wherein the computer records the measurement of the weight of the first dry product.
 5. The system of claim 1, wherein the first dry product is delivered to a blending hopper.
 6. The system of claim 1, wherein the first dry product is a first dry chemical.
 7. The system of claim 3, wherein the computer is in communication with the first meter and the first sensor.
 8. The system of claim 1, further comprising a second receiving container having a receiving portion and a delivery portion, the second receiving portion adapted to receive a second dry product; a second sensor engaged with the second receiving container and adapted to measure at least the weight of the second dry product; a second meter interconnected with the second container delivery portion and configured to receive the second dry product and deliver a user-selectable volume or rate of second dry product; a second air channel interconnected with the second meter and adapted to receive the second dry product from the second meter; a second hose interconnected with the second air channel and configured to receive the second dry product from the second air channel and the first dry product from the first hose; wherein the first hose and the second hose are in communication, wherein the blower fan is further adapted to urge the second dry product downstream and into the second hose, wherein a blended dry product of the first dry product and the second dry product is delivered to a delivery site.
 9. The system of claim 8, further comprising a diffuser positioned proximate to the second hose and adapted to interconnect to the second hose and decrease the speed of the blended dry product.
 10. The system of claim 8, further comprising a computer in communication with at least the first meter, the second meter, the first sensor, and the second sensor.
 11. The system of claim 8, wherein the first dry product is a first dry chemical and the second dry product is a second dry chemical.
 12. The system of claim 10, wherein the computer records a measurement of the weight of at least one of the first dry product and the second dry product.
 13. The system of claim 10, wherein the computer is in communication with the first meter and the first sensor.
 14. A method for delivery of a dry product to a delivery site, comprising: positioning a dry product delivery system proximate to a delivery site, the dry product delivery system comprising: a first receiving container having a receiving portion and a delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion and configured to receive the first dry product and deliver a user-selectable volume or rate of the first dry product; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; and a computer in communication with the first meter, the computer adapted to receive a user-selectable volume or rate of first dry product to the first air channel; inputting a selected volume or rate of first product to the first air channel; providing a first dry product to the first receiving container; wherein the first dry product as contained in the first hose is delivered to the delivery site.
 15. The method of claim 14, further comprising a diffuser interconnected with the first hose and adapted to decrease the speed of the first dry product.
 16. The method of claim 14, wherein the computer records the measurement of the weight of the first dry product.
 17. The method of claim 14, wherein the first dry product is a first dry chemical.
 18. A dry product delivery system, comprising: a first receiving container having a receiving portion and delivery portion, the first receiving portion adapted to receive a first dry product; a first sensor engaged with the first receiving container, and adapted to measure at least the weight of the first dry product; a first meter engaged with the first container delivery portion, receive the first dry product, and deliver a user-selectable volume or rate of the first dry product; a computer in communication with the first meter, the computer adapted to receive a user-selectable volume or rate of first dry product to the first air channel; a first air channel interconnected to the first meter and adapted to receive the first dry product from the first meter; a first hose interconnected to the first air channel and adapted to receive the first dry product from the first air channel; and a blower fan interconnected with the first air channel and adapted to urge the first dry product in the first air channel downstream and into the first hose; wherein the computer records the measurement of the weight of the first dry product, wherein the first dry product is delivered to a delivery site.
 19. The system of claim 18, wherein the first dry product is a first dry chemical.
 20. The system of claim 18, wherein the first air channel is interconnected to at least one of a hose, auger and conveyor. 